US8888771B2 - Clip-over disposable assembly for use with hemostat-style surgical instrument and methods of manufacturing same - Google Patents

Abstract

A clip-over disposable assembly includes a switch assembly and a disposable body. The disposable body includes a first disposable member, a second disposable member including first and second wall portions, and a third disposable member. The first wall portion defines a first aperture therethrough and a first cavity configured to receive therein a first portion of the switch assembly. The third disposable member includes a third wall portion, wherein a body of the second disposable member and the third wall portion define an opening configured to allow a shaft of a hemostat-style surgical instrument to pass therethrough. The second wall portion and the third wall portion cooperatively define a chamber in communication with the opening and configured to receive therein at least a portion of the shaft of the hemostat-style surgical instrument, wherein the at least a portion of the shaft is received in the chamber from an off-axis position.

Description

BACKGROUND

1. Technical Field

The present disclosure relates to electrosurgical instruments and, more particularly, to a clip-over disposable assembly for use with a hemostat-style surgical instrument, such as a bipolar forceps, and methods of manufacturing a clip-over disposable assembly.

2. Discussion of Related Art

Electrosurgery involves the application of thermal and/or electrical energy, such as radiofrequency energy, to coagulate, cauterize, cut and/or seal tissue. Electrosurgical devices have been developed for a variety of uses and applications.

Generally, the electrical configuration of electrosurgical devices can be categorized in two classifications: 1) monopolar electrosurgical devices; and 2) bipolar electrosurgical devices. Monopolar electrosurgical devices utilize one electrode associated with a cutting and/or cauterizing instrument and a remote return electrode, usually adhered externally to the patient. Bipolar devices utilize two generally opposing electrodes of a tissue treating portion (e.g., end effector) of an instrument, wherein the electrical current is generally limited to tissue disposed between the two electrodes.

A hemostat or forceps is a surgical device configured to use mechanical action between its jaws to constrict vessels and is commonly used in open surgical procedures to grasp, dissect and/or clamp tissue. Some hemostat-style surgical instruments, such as monopolar electrosurgical forceps and bipolar electrosurgical forceps, utilize both mechanical clamping action and electrosurgical energy to effect hemostasis by heating tissue and blood vessels to coagulate, cauterize, cut and/or seal tissue. By utilizing an electrosurgical forceps, a surgeon can cauterize, coagulate, desiccate and/or cut tissue and/or simply reduce or slow bleeding, by controlling the intensity, frequency and duration of the electrosurgical energy applied to tissue.

Monopolar electrosurgical forceps utilize one active electrode associated with the clamping end effector to deliver energy from an electrosurgical generator to tissue and a remote patient return electrode, usually positioned on the patient's thigh or back, to complete the electrical circuit between the electrosurgical generator and the patient. When electrosurgical energy is applied, the energy travels from the active electrode, to the surgical site, through the patient and to the return electrode.

Bipolar electrosurgical forceps utilize two electrodes, usually disposed on the inner facing or opposing surfaces of end effectors, which are, in turn, electrically coupled to an electrosurgical generator. Each electrode is charged to a different electric potential. When the end effectors are utilized to clamp or grasp tissue therebetween, the electrical energy can be selectively transferred from one electrode, through the intervening tissue to the other electrode.

In the use of many prior art electrosurgical instruments, cleaning and sterilizing is often impractical as electrodes and/or insulation can be damaged. It is known that electrically insulative materials, such as plastics, can be damaged or compromised by repeated sterilization cycles. To prolong the useful life of electrosurgical instruments, portions of an instrument may be disposable to allow the instrument to be used and sterilized a greater number of times.

SUMMARY

The present disclosure relates to a clip-over disposable assembly suitable for use with a hemostat-style surgical instrument. The clip-over disposable assembly includes a switch assembly and a disposable body configured for side-mounting onto the hemostat-style surgical instrument. The disposable body includes a first disposable member, a second disposable member and a third disposable member. The first disposable member includes first and second wall portions. The first wall portion defines a first aperture therethrough and a first cavity associated with the first aperture. The first cavity is configured to receive therein a first portion of the switch assembly. The second disposable member includes a body defining a second aperture therethrough and a second cavity associated with the second aperture. The second cavity is configured to receive therein a second portion of the switch assembly. The third disposable member includes a third wall portion, wherein the body of the second disposable member and the third wall portion define an opening configured to allow the shaft of the hemostat-style surgical instrument to pass therethrough, and wherein the second wall portion of first disposable member and the third wall portion cooperatively define a chamber in communication with the opening. The chamber is configured to receive therein at least a portion of the shaft of the hemostat-style surgical instrument, wherein the at least a portion of the shaft is received in the chamber from an off-axis position.

The present disclosure also relates to an electrosurgical instrument including a hemostat-style surgical instrument and a clip-over disposable assembly adapted to be releaseably attachable to the hemostat-style surgical instrument The clip-over disposable assembly includes a switch assembly, a first disposable member, a second disposable member, and a third disposable member. The first disposable member includes first and second wall portions. The first wall portion defines a first aperture therethrough and a first cavity associated with the first aperture. The first cavity is configured to receive therein a first portion of the switch assembly. The second disposable member includes a body defining a second aperture therethrough and a second cavity associated with the second aperture. The second cavity is configured to receive therein a second portion of the switch assembly. The third disposable member includes a third wall portion, wherein the third wall portion and the second wall portion cooperatively define a chamber configured to receive therein at least a portion of a shaft of the hemostat-style surgical instrument.

The present disclosure also relates to a method of manufacturing a clip-over disposable assembly including the initial steps of providing a switch assembly, and providing first and second disposable members configured to form an internal chamber when the first and second disposable members are coupled together. The chamber is configured to accommodate at least a portion of the switch assembly therein. The method also includes the steps of coupling the second disposable member to the first disposable member, wherein a first portion of a user-actuatable button of the switch assembly is disposed in association with an outer peripheral surface of the first disposable member and a second portion of the user-actuatable button is disposed in association with an outer peripheral surface the second disposable member, and providing a third disposable member including a wall portion configured to form a chamber when the first and third disposable members are coupled together, wherein the chamber configured to receive therein at least a portion of a shaft of a hemostat-style surgical instrument, and coupling the third disposable member to the first disposable member.

The present disclosure also relates to a method of manufacturing a clip-over disposable assembly including the initial steps of providing a switch assembly, providing a first disposable member, and providing a second disposable member. The first disposable member includes first and second wall portions. The first wall portion defines a first aperture therethrough and a first cavity associated with the first aperture. The first cavity is configured to receive therein a first portion of the switch assembly. The second disposable member includes a body defining a second aperture therethrough and a second cavity associated with the second aperture. The second cavity is configured to receive therein a second portion of the switch assembly. The method also includes the steps of positioning the first portion of the switch assembly into the first cavity, positioning the second portion of the switch assembly into the second cavity, coupling the second disposable member to the first disposable member, providing a third disposable member including a third wall portion, and coupling the third disposable member to the first disposable member, wherein the third wall portion and the second wall portion cooperatively define a chamber configured to receive therein at least a portion of a shaft of a hemostat-style surgical instrument.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects and features of the presently-disclosed clip-over disposable assembly for use with a hemostat-style surgical instrument and methods of manufacturing a clip-over disposable assembly will become apparent to those of ordinary skill in the art when descriptions of various embodiments thereof are read with reference to the accompanying drawings, of which:

FIG. 1 is a side view of a bipolar forceps in accordance with an embodiment of the present disclosure;

FIG. 2 is an enlarged, cross-sectional view taken along line2-2 ofFIG. 1;

FIG. 3 is a top view of a switch assembly in accordance with an embodiment of the present disclosure;

FIG. 4 is a side view of the switch assembly ofFIG. 3 in accordance with an embodiment of the present disclosure;

FIG. 5 is a flowchart illustrating a method of manufacturing a clip-over disposable assembly in accordance with an embodiment of the present disclosure; and

FIG. 6 is a flowchart illustrating a method of manufacturing a clip-over disposable assembly in accordance with another embodiment of the present disclosure.

DETAILED DESCRIPTION

Hereinafter, embodiments of the presently-disclosed clip-over disposable assembly for use with a hemostat-style surgical instrument and methods of manufacturing a clip-over disposable assembly are described with reference to the accompanying drawings. Like reference numerals may refer to similar or identical elements throughout the description of the figures. As shown in the drawings and as used in this description, and as is traditional when referring to relative positioning on an object, the term “proximal” refers to that portion of the apparatus, or component thereof, closer to the user and the term “distal” refers to that portion of the apparatus, or component thereof, farther from the user.

As it is used in this description, “transmission line” generally refers to any transmission medium that can be used for the propagation of signals from one point to another.

Various embodiments of the present disclosure provide electrosurgical instruments suitable for sealing, cauterizing, coagulating/desiccating and/or cutting vessels and vascular tissue. Embodiments may be implemented using electromagnetic radiation at microwave frequencies or at other frequencies.

Various embodiments of the presently-disclosed electrosurgical instrument including a hemostat-style surgical instrument and a clip-over disposable assembly are suitable for use with open and/or laparoscopic surgical procedures. Although the following description describes the use of a bipolar forceps, the teachings of the present disclosure may also apply to a monopolar forceps, or other suitable type of hemostat-style surgical instrument.

FIG. 1 shows abipolar forceps10 according to an embodiment of the present disclosure that includes amechanical forceps20 and a clip-overassembly50. Clip-overassembly50 is configured to accommodate aswitch assembly100, partly shown by phantom lines inFIG. 1. An embodiment of a switch assembly, such as theswitch assembly100 ofFIG. 1, in accordance with the present disclosure, is shown in more detail inFIGS. 3 and 4. It will be understood, however, that other switch assembly embodiments may also be used. Clip-overassembly50, which is described in more detail later in this disclosure, is generally configured to be releaseably attachable to themechanical forceps20.

Mechanical forceps20 includes first andsecond members9 and11. First andsecond members9 and11 each include anelongated shaft12 and14, respectively.Shafts12 and14 each include aproximal end13 and15 and adistal end17 and19, respectively. Eachproximal end13,15 of eachshaft portion12,14 includes ahandle member16 and18, respectively, attached thereto to allow a user to effect movement of at least one of theshaft portions12 and14 relative to one another. Extending from thedistal end17 and19 of eachshaft portion12 and14 areend effectors22 and24, respectively.End effectors22 and24 are movable relative to one another in response to movement of thehandle members16 and18.

In some embodiments, as shown inFIG. 1,shaft portions12 and14 are affixed to one another at a point proximate theend effectors22 and24 about apivot25 such that movement of thehandle members16 and18 impart movement of theend effectors22 and24 from an open configuration, wherein theend effectors22 and24 are disposed in spaced relation relative to one another, to a clamping or closed configuration, wherein theend effectors22 and24 cooperate to grasp tissue therebetween. In alternative embodiments not shown, theforceps10 can be designed such that movement of one or both of thehandle members16 and18 will only cause one of the end effectors, e.g.,22, to move with respect to the other end effector, e.g.,24.

End effector24 generally includes an upper orfirst jaw member44.End effector22 generally includes a second orlower jaw member42. In some embodiments,shaft members12 and14 of themechanical forceps20 may be designed to transmit a particular desired force to opposing inner-facing surfaces of thejaw members42 and44.

Examples of shaft member and end effector embodiments are disclosed in commonly assigned U.S. Pat. No. 6,277,117 entitled “OPEN VESSEL SEALING FORCEPS WITH DISPOSABLE ELECTRODES”, commonly assigned U.S. Pat. No. 6,796,981 entitled “VESSEL SEALING SYSTEM”, commonly assigned U.S. Pat. No. 7,510,556 entitled “VESSEL SEALING INSTRUMENT”, and commonly assigned U.S. patent application Ser. No. 11/232,174 filed on Sep. 21, 2005, entitled “MECHANISM FOR DIVIDING TISSUE IN A HEMOSTAT-STYLE INSTRUMENT”.

Forceps10 includes acable assembly62 configured to operably couple theforceps10 to an electrosurgicalpower generating source28, e.g., a microwave or RF electrosurgical generator.Cable assembly62 may be formed from a suitable flexible, semi-rigid or rigid cable, and may connect directly to the electrosurgicalpower generating source28. In some embodiments, thecable assembly62 connects theforceps10 to aconnector63, which further operably connects theinstrument10 to the electrosurgicalpower generating source28.Cable assembly62 may be internally divided into a plurality of conductors (e.g.,61a,61b,61cshown inFIG. 2) configured to transmit electrosurgical energy through respective feed paths to theend effectors22 and24 and/or transmitting electrical signals to control delivery of electrosurgical energy and/or feedback signals to control the electrosurgicalpower generating source28.

Electrosurgicalpower generating source28 may include any energy source, e.g., electrosurgical generator, suitable for use with electrosurgical devices, and may be configured to provide ultrasound, radiofrequency (RF), microwaves, laser energy and/or various frequencies of electromagnetic energy. Examples of electrosurgical generators that may be suitable for use as a source of electrosurgical energy are commercially available under the trademarks FORCE EZ™, FORCE FX™, SURGISTAT™ II, and FORCE TRIAD™ offered by Covidien.Cable assembly62 may additionally, or alternatively, provide a conduit (not shown) configured to provide coolant fluid from a coolant source (not shown) to one or more components of theforceps10.Forceps10 may alternatively be configured as a wireless device and/or battery powered.

As shown inFIGS. 1 and 2, clip-overassembly50 is designed to work in combination with themechanical forceps20. Clip-overassembly50 is designed to clip around themechanical forceps20 from the side and includes adisposable body56 configured to releaseably engage one of the shaft members, e.g.,14, of themechanical forceps20. In some embodiments, as shown inFIG. 2,disposable body56 includes a firstdisposable member57, a seconddisposable member58 and a thirddisposable member59, wherein the seconddisposable member58 is coupled to the firstdisposable member57 to cooperatively define atab portion53, and the thirddisposable member59 is coupled to the firstdisposable member57 to cooperatively define a chamber “C”, wherein the chamber “C” is disposed in communication with an opening “O” defined by the seconddisposable member58 and the thirddisposable member59.Tab portion53 is configured to accommodate theswitch assembly100 therein and suitably shaped to fit within the region “R” (FIG. 1) defined between the opposingshaft portions12 and14.

Firstdisposable member57, the seconddisposable member58 and/or the thirddisposable member59 may include a plurality of mechanical interfaces disposed at various positions along their respective interiors to effect mechanical engagement with one another. In some embodiments, either male or female mechanical interfaces or a combination of mechanical interfaces may be disposed within the seconddisposable member58 and/or the thirddisposable member59 with mating mechanical interfaces disposed on or within the firstdisposable member57. Firstdisposable member57, seconddisposable member58 and the thirddisposable member59 may be assembled together with the aid of alignment pins, detents, snap-like interfaces, tongue and groove interfaces, locking tabs, adhesive ports, etc., utilized either alone or in combination for assembly purposes. Any suitable joining method may be used to attach (or clip, connect, couple, fasten, secure, etc.) the second and thirddisposable members58,59 to the firstdisposable member57. In alternative embodiments not shown, the firstdisposable member57 and the thirddisposable member59 are integrally formed as a single unitary body by a suitable molding process, such as injection molding.

Firstdisposable member57, the seconddisposable member58, and the thirddisposable member59 may be formed in whole or in part of any suitable electrically non-conductive material, e.g., a suitable polymeric or ceramic material. In some embodiments, the firstdisposable member57, the seconddisposable member58 and/or the thirddisposable member59 are formed at least in part from a rigid material, such as polyamide or other plastic, or a composite material having low electrical conductivity, e.g., glass-reinforced polymers. In some embodiments, the firstdisposable member57, the seconddisposable member58 and/or the thirddisposable member59, or portions thereof, may be formed from metal, thermoplastic, e.g., polycarbonate, composites, e.g., plastic-metal or ceramic-metal composites, or other materials.

As shown inFIG. 2, firstdisposable member57 includes afirst wall portion51 and asecond wall portion52.First wall portion51 defines afirst aperture71 therethrough and afirst cavity76 associated with thefirst aperture71.First cavity76 is configured to receive therein a first portion (e.g.,46 shown inFIGS. 2 and 4) of theswitch assembly100. Seconddisposable member58 includes abody54 defining a second aperture74 therethrough and asecond cavity78 associated with the second aperture74.Second cavity78 is configured to receive therein a second portion (e.g.,48 shown inFIGS. 2 and 4) of theswitch assembly100. Thirddisposable member59 includes athird wall portion55.Third wall portion55 of the thirddisposable member59 and thebody54 of the seconddisposable member58 are adapted to cooperatively define an opening “0” configured to allow one of the shaft members, e.g.,14, of themechanical forceps20 to pass therethrough.Third wall portion55 of the thirddisposable member59 and thesecond wall portion52 of firstdisposable member57 are adapted to cooperatively define a chamber “C” configured to receive therein at least a portion of one of the shaft members, e.g.,14, of themechanical forceps20, wherein chamber “C” is disposed in communication with the opening “O”. In some embodiments, at least a portion of thecable assembly62 is housed within the clip-overassembly50.

Although the clip-overassembly50 is adapted to releaseably-engage themechanical forceps20,bipolar forceps10 can be manufactured wherein the clip-overassembly50 may be permanently or semi-permanently affixed to themechanical forceps20 by any suitable process including without limitation mechanical fasteners, grooves, flanges, adhesive bonding, welding processes, e.g., laser welding, mechanical interlock, snaps, bent tabs, or other suitable joining method may be used to attach (or clip, connect, couple, fasten, secure, etc.) the clip-overassembly50 to themechanical forceps20.

As cooperatively shown inFIGS. 1 and 2,switch assembly100 include user-actuatable button “B” including two user-accessible contact areas4aand4b(e.g., disposed on opposite sides of the mechanical forceps20) configured to allow finger actuation of a switch “S”. Switch “S” may include any suitable switch, e.g., a joystick switch or other control mechanism, and may be disposed in operative communication with a source ofelectrosurgical energy28 and/or a processor unit (not shown) configured to control delivery of electrosurgical energy to theforceps10.

In some embodiments, as shown inFIGS. 3 and 4,contact areas4aand4bmay include one or more features, e.g., protrusions or contact bumps41 raised on the face of thecontact areas4aand4b, to increase operability and/or enhance ease-of-use of the button “B”. The shape, size and spacing of individual contact bumps41 may be varied from the configuration depicted inFIGS. 3 and 4.

As shown inFIGS. 3 and 4,switch assembly100 includes aconnector member30 adapted to operably couple the button “B” and the switch “S”.Connector member30 includes a post member “P” operably associated between the button “B” and the switch “S”. As shown inFIG. 3, post member “P” includes apost body32 including two prong-like portions34 and36 extending outwardly from theconnector member30.Connector member30 includes afirst connector portion31 disposed to place thecontact areas4aand4bin operative association with thepost body32, and may include asecond connector portion33 disposed to place thepost body32 in operative association with the switch “S”. In some embodiments, thepost body32 bisects or otherwise divides theconnector member30 into thefirst connector portion31 and thesecond connector portion33.

In some embodiments, button “B” includes aflange45 disposed in association with the first andsecond contact areas4aand4b.Flange45 is configured to facilitate positioning of the button “B”, and may be adapted to reduce fluid egress, e.g., to reduce the likelihood of damage to the switch “S” due to fluid egress. In some embodiments,flange45 is configured to facilitate positioning of the first user-accessible contact area4brelative to thefirst aperture71 and positioning of the second user-accessible contact area4arelative to the second aperture74.

As shown inFIG. 3,connector portion30 defines a first axis “A₁-A₁” along the longitudinal direction of theconnector portion30, and a transverse or second axis “A₂-A₂” perpendicular thereto.Post body32 defines a third axis “A₃-A₃” along the longitudinal direction of thepost body32, wherein the third axis “A₃-A₃” is at least substantially parallel to the second axis “A₂-A₂”. Button “B” is selectively actuatable by depression of one or both of thecontact areas4a,4bto cause movement of thepost body32 relative to the second axis “A₂-A₂”; which, in turn, allows selective activation of the switch “S”.

In some embodiments,switch assembly100 is adapted to preclude activation of the switch “S” if the applied force to one or both of thecontact areas4a,4bdoes not result in deflection of the third axis “A₃-A₃” by at least a predetermined angle (e,g., relative to the second axis “A₂-A₂”), e.g., to avoid or reduce unintended activation of the switch “S”. In some embodiments, when user-applied force to one or both of thecontact areas4a,4bcauses movement of thefirst connector portion31 resulting in deflection of the third axis “A₃-A₃” by at least a predetermined angle (e.g., relative to the second axis “A₂-A₂”), the resultant movement of thesecond connector portion33 results in activation of the switch “S”.

Hereinafter, methods of manufacturing a clip-over disposable assembly in accordance with the present disclosure are described with reference toFIGS. 5 and 6. It is to be understood that the steps of the methods provided herein may be performed in combination and in a different order than presented herein without departing from the scope of the disclosure.

FIG. 5 is a flowchart illustrating a method of manufacturing a clip-overdisposable assembly50 according to an embodiment of the present disclosure. Instep510, aswitch assembly100 is provided.Switch assembly100 includes a user-actuatable button “B” including two user-accessible contact areas4aand4b.

Instep520, first and seconddisposable members57,58 are provided. The first and seconddisposable members57,58 are configured to form aninternal chamber76,78 when coupled together. Thechamber76,78 is configured to accommodate at least aportion46,48 of theswitch assembly100 therein. The first and seconddisposable members57,58 may be formed in whole or in part of any suitable electrically non-conductive material, e.g., a suitable polymeric or ceramic material.

Instep530, the seconddisposable member58 is coupled to the firstdisposable member57, wherein afirst portion4bof the user-actuatable button “B” is disposed in association with an outer peripheral surface of the firstdisposable member57 and asecond portion4aof the user-actuatable button “B” is disposed in association with an outer peripheral surface the seconddisposable member58. Any suitable joining method, e.g., ultrasonic welding, may be used to couple the seconddisposable member58 to the firstdisposable member57.

Instep540, a thirddisposable member59 is provided. Thirddisposable member59 includes awall portion55 configured to form a chamber “C” when the first and thirddisposable members57,59 are coupled together. The chamber “C” is configured to receive therein at least a portion of ashaft14 of a hemostat-stylesurgical instrument20.

Instep550, the thirddisposable member59 is coupled to the firstdisposable member57. In some embodiments, one or more conductors (e.g., threeconductors61a,61b,61c) suitable for transmitting electrosurgical energy through respective feed paths to endeffectors22 and24 of aninstrument20 and/or electrical signals to control delivery of electrosurgical energy and/or feedback signals to control a source ofelectrosurgical energy28 are over-molded prior to coupling the thirddisposable member59 to the firstdisposable member57, instep550.

FIG. 6 is a flowchart illustrating a method of manufacturing a clip-overdisposable assembly50 according to an embodiment of the present disclosure. Instep610, aswitch assembly100 is provided.

Switch assembly100 includes a user-actuatable button “B” including first and second user-accessible contact areas4aand4b. In some embodiments, theswitch assembly100 also includes apost member30 including apost body32, wherein thepost body32 defines a longitudinal axis “A₃-A₃” transverse to the longitudinal axis “A₁-A₁” of theconnector member30. In some embodiments, thepost body32 bisects or otherwise divides theconnector member30 into afirst connector portion31 and asecond connector portion33.

Instep620, a firstdisposable member57 is provided. Firstdisposable member57 includes first andsecond wall portions51 and52, respectively. Thefirst wall portion51 defines afirst aperture71 therethrough and afirst cavity76 associated with thefirst aperture71. Thefirst cavity76 is configured to receive therein afirst portion46 of theswitch assembly100.

Instep630, a seconddisposable member58 is provided. Seconddisposable member58 includes abody54 defining a second aperture74 therethrough and asecond cavity78 associated with the second aperture74. Thesecond cavity78 is configured to receive therein asecond portion48 of theswitch assembly100.

Instep640, thefirst portion46 of theswitch assembly100 is positioned into thefirst cavity76. The first user-accessible contact area4bmay be disposed in association with thefirst aperture71.

Instep650, asecond portion48 of theswitch assembly100 is positioned into thesecond cavity78. The second user-accessible contact area4bmay be disposed in association with the second aperture74.

Instep660, the seconddisposable member58 is coupled to the firstdisposable member57. Any suitable joining method, e.g., ultrasonic welding, may be used to couple the seconddisposable member58 to the firstdisposable member57.

Instep670, a thirddisposable member59 is provided. Thirddisposable member59 includes athird wall portion55.

Instep680, the thirddisposable member59 is coupled to the firstdisposable member57, wherein thethird wall portion55 and thesecond wall portion52 cooperatively define a chamber “C” configured to receive therein at least a portion of ashaft14 of a hemostat-stylesurgical instrument20.

The above-described clip-over disposable assembly embodiments including a switch assembly and a disposable body configured for side-mounting onto a hemostat-style surgical instrument are suitable for use with various types of hemostat-style surgical instruments, such as without limitation, electrosurgical forceps, and may be suitable for a variety of uses and applications. Embodiments may be used in conjunction with electrosurgical devices suitable for use with open and/or laparoscopic surgical procedures.

The above-described methods of manufacturing a clip-over disposable assembly may be used in conjunction with a variety of electrosurgical devices adapted for treating tissue, such as bipolar electrosurgical forceps, monopolar electrosurgical forceps, and other hemostat-style surgical instruments. The above-described methods designed for ease of assembly a clip-over disposable assembly including a switch assembly and a disposable body configured for side-mounting onto a hemostat-style surgical instrument are suitable for use with a variety of types of hemostat-style surgical instruments.

Although embodiments have been described in detail with reference to the accompanying drawings for the purpose of illustration and description, it is to be understood that the inventive processes and apparatus are not to be construed as limited thereby. It will be apparent to those of ordinary skill in the art that various modifications to the foregoing embodiments may be made without departing from the scope of the disclosure.

Claims (17)

What is claimed is:

1. A clip-over disposable assembly suitable for use with a hemostat-style surgical instrument, the clip-over disposable assembly comprising:

a switch assembly including a switch; and

a disposable body configured for side-mounting onto a shaft of the hemostat-style surgical instrument, the disposable body including:

a first disposable member including first and second wall portions, the first wall portion defining a first aperture therethrough and a first cavity associated with the first aperture, the first cavity configured to receive therein a first portion of the switch assembly;

a second disposable member including a body defining a second aperture therethrough and a second cavity associated with the second aperture, the second cavity configured to receive therein a second portion of the switch assembly; and

a third disposable member including a third wall portion, wherein the body of the second disposable member and the third wall portion define an opening configured to allow the shaft of the hemostat-style surgical instrument to pass therethrough, and wherein the second wall portion of first disposable member and the third wall portion cooperatively define a chamber in communication with the opening, the chamber configured to receive therein at least a portion of the shaft of the hemostat-style surgical instrument, wherein the at least a portion of the shaft is received in the chamber from an off-axis position.

2. The clip-over disposable assembly ofclaim 1, wherein the switch assembly further includes a user-actuatable button including first and second user-accessible contact areas.

3. The clip-over disposable assembly ofclaim 2, wherein the first user-accessible contact area is disposed in association with the first aperture and the second user-accessible contact area is disposed in association with the second aperture.

4. The clip-over disposable assembly ofclaim 3, wherein the first user-accessible contact area includes a flange associated therewith configured to facilitate positioning of the first user-accessible contact area relative to the first aperture.

5. The clip-over disposable assembly ofclaim 3, wherein the second user-accessible contact area includes a flange associated therewith configured to facilitate positioning of the second user-accessible contact area relative to the second aperture.

6. The clip-over disposable assembly ofclaim 2, wherein the switch assembly further includes a connector member adapted to operably couple the button and the switch, the connector member defining a longitudinal axis.

7. The clip-over disposable assembly ofclaim 5, wherein the connector member includes a post member operably associated between the button and the switch.

8. The clip-over disposable assembly ofclaim 7, wherein the post member includes a post body defining a longitudinal axis transverse to the longitudinal axis of the connector member.

9. The clip-over disposable assembly ofclaim 8, wherein the connector member includes a first connector portion disposed to place the first and second contact areas in operative association with the post body.

10. The clip-over disposable assembly ofclaim 9, wherein the connector member further includes a second connector portion disposed to place the post body in operative association with the switch.

11. An electrosurgical instrument, comprising:

a hemostat-style surgical instrument;

a clip-over disposable assembly adapted to be releaseably attachable to the hemostat-style surgical instrument, the clip-over disposable assembly including:

a switch assembly;

a first disposable member including first and second wall portions, the first wall portion defining a first aperture therethrough and a first cavity associated with the first aperture, the first cavity configured to receive therein a first portion of the switch assembly;

a second disposable member including a body defining a second aperture therethrough and a second cavity associated with the second aperture, the second cavity configured to receive therein a second portion of the switch assembly; and

a third disposable member including a third wall portion, wherein the third wall portion and the second wall portion cooperatively define a chamber configured to receive therein at least a portion of a shaft of a hemostat-style surgical instrument.

12. The electrosurgical instrument ofclaim 11, wherein the hemostat-style surgical instrument is adapted to direct energy to tissue.

13. The electrosurgical instrument ofclaim 11, wherein the hemostat-style surgical instrument is a mechanical forceps.

14. The electrosurgical instrument ofclaim 11, further comprising a cable assembly adapted to connect to a source of electrosurgical energy.

15. A method of manufacturing a clip-over disposable assembly, comprising the steps of:

providing a switch assembly;

providing first and second disposable members configured to form an internal chamber when the first and second disposable members are coupled together, the chamber configured to accommodate at least a portion of the switch assembly therein;

coupling the second disposable member to the first disposable member, wherein a first portion of a user-actuatable button of the switch assembly is disposed in association with an outer peripheral surface of the first disposable member and a second portion of the user-actuatable button is disposed in association with an outer peripheral surface the second disposable member;

providing a third disposable member including a wall portion configured to form a chamber when the first and third disposable members are coupled together, the chamber configured to receive therein at least a portion of a shaft of a hemostat-style surgical instrument; and

coupling the third disposable member to the first disposable member.

16. The method of manufacturing a clip-over disposable assembly ofclaim 15, wherein the hemostat-style surgical instrument is adapted to direct energy to tissue.

17. The method of manufacturing a clip-over disposable assembly ofclaim 15, wherein the switch assembly includes an integral joystick switch.

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